Hi, on The woodpecker this week, I make a cryptex.
This is the 3D model of the Cryptex I did,
just like in The Da Vinci Code movie. This was my son's Christmas gift last year.
But to be honest, this wasn't what I had in mind.
I wanted to make a perpetual motion machine; but it didn't work.
So I made another one, and that one didn't work either..
So I decided to make something different, and guess what?
You're right it didn't work either.
But this didn't stop me; I made a fourth one, which looks pretty similar to the second one.
You can see it at the top left of the screen, but just like the others; it didn't work.
I didn't want to quit just yet, so I made this totally different model;
but just like the others, it didn't work...
Then I make part of another model that I saw on the net,
but I guess they had a motor driving it.
That's when I decided to make a Cryptex; at least this is simple to make.
So after drawing what I want, I look around for some scrap wood and start the build.
I begin by surfacing a piece of walnut.
But my wood is way too thick; I rip it thinner.
I rip it just a bit thicker than three quarter.
I finish the cut with the band saw.
But this leaves a less than perfect surface, so I go back to the jointer and sand all the pieces to the right thickness.
My drum sander leaves nasty scratches so I always need to use a hand sander to finish the job.
Now that I have all the wood I need, I can start.
The first thing I do, is cut the patterns I made.
Then, I stick them on the wood I want to use.
When the patterns are all in place, I put packing tape on top,
but to be honest; it was useless.
Then, I just cut all the parts that I'll be using.
After marking the centre of all the rings, I drill a small hole right through.
Now I need to drill a big shallow half inch hole in the middle of each ring.
To figure the depth, I lay the bit on top of the wood, and adjust the drill press stop with a half inch setup block.
Then I can drill all seven holes.
On the other side, I drill a smaller hole.
Then I roughly cut each ring.
Ok, I have all the rings I need. I just need to make them round.
So, after making sure the sander table is square, I sand all of them up to the line.
But when I'm done, nothing is holding the rings together.
So I rout a quarter inch rabbet all around each one.
Now that they fit into each other perfectly,
I go back to the sander, just to be sure they're the same size.
Now, I can sand them smooth.
I don't need the patterns anymore so I remove them.
One of my patterns is the space in between each letter, I cut it and use it to mark the space for each letter.
Then I make small lines with the scroll saw.
After the rings' final sanding, I can mark the lettering.
But writing them by hand looks awful so I use some letter stamps.
This is the kit I found.
Applying the letters is quite simple, but it's true this kit is mostly for young children...
When I'm done with the letters, I can start working on both ends.
I begin by ripping a strip of walnut.
Then I rip it thinner.
Now I can cut two squares.
I mark the centre of each one.
On one of them, I drill a shallow hole
and on the other one, a through hole.
I use the through hole to help me drill a big hole from both sides of the square.
I carve a woodpecker on the other square.
A wooden tube will be inserted inside the rings,
so I'll turn one from this piece of wood.
The first thing I do, is cut all four corners.
Then I turn it round.
I stop from time to time to check if the rings will fit over the cylinder.
I stop from time to time to check if the rings will fit over the cylinder.
After measuring the depth of the hole, I cut it just a little bit longer.
This will be A1.
The cylinder will be inside the rings and the ends will be just like that.
But to keep the ends together, I need to drill a hole in each corner.
Then I round each one.
Finally, I rout a roundover around each end.
Last thing to do, is a little hand sanding.
Now I need to cut a small disk, which will help me align the first ring.
After drilling a hole in its centre, I apply a bit of glue and screw it to the end.
Then, I can glue the first ring and apply clamp pressure.
Another ring is glued onto the end which has a big hole,
and just like for the other ring, I apply clamp pressure.
Now, I need to take care of the cylinder cap.
I begin by turning a piece of maple, to the size I want the cap to be.
When I'm happy with its shape, I sand it real nice,
turn it around and make the tenon that will be inside the cylinder.
That is how everything will go together.
But the end of the cylinder needs a little bit of work.
Now, I can mark where I need to put some nails to lock this.
All done; but the lines are misaligned.
I trace them better and find the bit size I need for the nails that I'll be using and drill six holes, taking care to drill them in a straight line.
Now I have to erase all the lines.
Then I can cut an opening to access the inside of the cylinder.
But I have a hard time starting the cut.
Eventually, I manage to cut an opening; but not without damaging the exterior.
I really don't like that...
So I make a brand new cylinder.
But this time, to help me, I make the first cut with a hand saw before returning to the scroll saw.
But if I had to do this again, I would just use a fret saw; that way I would have more control over the cut.
Now I can glue the nails in place.
I pour instant glue inside the holes and drive the nails in place.
When the glue is dry, I cut the nails
and sand them to the same height.
Then I round over their tip.
Now, I can glue the cylinder and its cap together.
While the glue dries, I mark the secret code inside each ring
and cut a notch at the scroll saw.
This is how the inside looks now.
With all the notches aligning, I can insert the cylinder in place.
But to finish this, I need four corner posts.
I begin by measuring the length I need and cut the four dowels.
But when I try to insert them in their holes, they don't fit. They're just a tad too big.
I fix this right away.
After a last dry fit, I'm ready to glue the Cryptex.
I begin by gluing the four posts on one walnut end.
Then I can spray the first coat of lacquer.
When I spray the dowels, I cover their other ends to make sure no finish ends up there.
When the lacquer is really dry, I glue everything together.
But when I'm done, I have a major problem;
I can't open the Criptex...
I have no mark on the cylinder cap telling me where the nails should be aligned.
I'm forced to take this apart.
Luckily for me, the glue wasn't totally set yet.
Then, I scratch a fine line on the cylinder cap. So fine it's even hard to see.
Then I re-assemble it again.
When the glue is dry, I spray another coat of finish.
The next day, I apply wax on the cylinder's exterior, to help it turn better.
And with that, Franky's Christmas present is finished.
At this exact moment, I knew he would love it.
Look at his face on Christmas eve.
It took him an hour to find the solution, and that's because Renée showed him the scratch.
One thing I can say is that I had more fun making this Criptex than all the failed perpetual motion machines.
And maybe I've managed to inspire you to also make a Criptex as a Christmas present.
But until then you can still follow me on The Woodpecker.
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